Modular reusable vehicle shipping crate

ABSTRACT

A shipping crate for shipping objects such as all-terrain vehicles and personal water-crafts. The shipping crate includes a top frame structure and a bottom frame structure. The crate may include an extension removably connectable to the bottom frame structure. The crate may include at least one pivotally mounted leg.

I. CROSS REFERENCE TO RELATED APPLICATIONS

This continuation-in-part application claims benefit under 35 U.S.C. §120 of patent application Ser. No. 11/172,860 filed on Jul. 5, 2005, U.S. Pat. No. 7,350,662, and benefit under 35 U.S.C. §119 to Provisional Application 60/588,046 filed on Jul. 15, 2004, the entire contents of both applications are incorporated by reference herein.

II. FIELD OF THE INVENTION

The present invention is directed to a shipping crate. More particularly, the present invention is directed to a shipping crate for transporting objects such as, for example, an all-terrain vehicle (ATV) or personal water craft (PWC). The shipping crate is constructed with a sturdy frame such that the contents of the container are protected from external damage while the crate and its contents are being shipped from one location to another, for example, via a tractor trailer, a railcar or a boat.

III. BACKGROUND OF THE INVENTION

Often, upon reaching their appointed destination and being unpacked, shipping crates for vehicles such as ATVs and PWCs are disposed of by the vehicle dealer or transporter. A shipping crate in accordance with the present inventive design, however, is substantially 100% recyclable.

When certain articles of manufacture are shipped, it is known to enclose the articles in a shipping container, or crate, in order to protect the article from damage caused by objects that would otherwise come in contact with the article, or from damage caused by the article being dropped or otherwise mishandled. When the weight and/or value of the article being shipped within a particular crate are relatively large, the complexity and sturdiness of the respective crate housing the article is also relatively large. Accordingly, for articles such as ATVs and PWCs, metal shipping crates are typically employed.

Several such shipping crates capable of shipping ATVs and PWCs have been proposed. However, the previously proposed crates suffer from various disadvantages as discussed below.

For example, U.S. Pat. No. 6,726,041, to Dunn, discloses a metal shipping crate for shipping an ATV. According to the Dunn patent disclosure, the disclosed crate is easily modifiable to accommodate different sizes of cargo, e.g., ATVs. According to the Dunn disclosure, the Dunn crate can be either discarded or reused after the cargo has been removed.

The Dunn shipping crate is made of tubular metal rails with separate top and bottom portions that are joined together by tubular metal posts. Further, the bottom portion of the Dunn crate is reportedly adjustable to accommodate various sizes of cargo, as needed.

The Dunn shipping crate, however, suffers from certain disadvantages and inefficiencies which are resolved by a crate in accordance with the present invention. In particular, although the Dunn shipping crate can likely be disassembled after it is used for shipping an ATV, and can be returned to the shipper to be reused, the disassembled Dunn crate takes up an inordinate amount of space, thereby, wasting valuable cargo space when shipping the disassembled crate back to the shipper for reuse.

Further, crates like the one disclosed in Dunn are susceptible to “racking” when weight is placed on top of the crate. Racking, according to this disclosure, refers to a phenomenon where the top of the crate moves independently from the bottom of the crate. Oftentimes, when a structure, such as the rectangular Dunn crate, is moved rapidly, such as by being transported in a truck, the top of the structure will move out of alignment with the bottom of the structure and place undue strain on the joints of the structure. This “racking” effect is exacerbated as the amount of weight placed on top of the structure is increased, such as when heavy shipping crates are stacked on top of each other.

A crate in accordance with U.S. Published Patent Application No. 20040188307 to Beck, suffers from at least the same disadvantages as those described above in regard to the Dunn crate. The ATV shipping crate disclosed in the Beck application includes a base frame and a top frame. Corner posts are received in corresponding sockets located at respective corners of the top and bottom frames. The, top and bottom frames of the Beck crate are maintained a certain distance from each other, the respective distance being determined by the length of the posts.

If the Beck crate were disassembled after use, for example to return the empty crate to the shipper for reuse, the Beck crate would take up an excessive amount of valuable space on the vehicle of the return-shipper. Also, like the Dunn crate above, the Beck crate is susceptible to racking. Thus, when used to carry stacked heavy loads, the joints, particularly in the corners of the crate, are vulnerable to cracking, or other forms of deterioration.

IV. SUMMARY OF THE INVENTION

Illustrative, non-limiting embodiments of the present invention overcome the aforementioned and other disadvantages associated with related art shipping crates. Also, the present invention is not required to overcome the disadvantages described above and an illustrative non-limiting embodiment of the present invention may not overcome any of the problems described above.

It is an aspect of the present invention to provide a shipping crate with top and bottom portions thereof that can be compacted with one another when the crate is empty to minimize the amount of space occupied by the empty, disassembled, crate.

It is a further aspect of the present invention to provide a shipping crate that provides a sturdy container in which to transport large, heavy, objects.

It is a further aspect of the present invention to provide a shipping crate with a sturdy frame and which avoids excessive deflection of the frame components and provides continuous rigidity throughout the frame at all times, e.g., when an article is stored within and when disassembled and compacted for return to the shipper or other location when empty.

Further, aspects of a shipping crate consistent with the present invention include easy compaction to a much smaller size after the contents have been removed so as to enable efficient, space-saving, return of the empty containers; sturdy construction to avoid deflection of the crate during transport and to avoid “hopping”.

A crate in accordance with the present invention comprises a top portion including a plurality of top cross-members each fixedly attached to one or more top corner portions and a bottom portion comprising a plurality of bottom cross-members each fixedly attached to one or more bottom corner portions. To provide a sturdy configuration and to permit efficient compaction of the crate when empty, the top corner portions and the bottom corner portions are operable to telescopically engage each other. Each of the top, bottom and corner portions can be made of tubular metal components or other suitable material that provides a sturdy frame and telescoping engagement of the components.

Also, in accordance with the present invention, to accommodate the telescoping engagement of the corner components, the outer dimension of each of either the top or bottom corner portions is smaller than the inner dimension of the other of the top or bottom corner portions. Leg portions, each comprising two ends and each end being operable to engage a respective top or bottom corner portion can also be used to construct a shipping crate in accordance with the present invention. The inner dimension of one of the ends of the legs is such that it can telescopically fit into either a top or bottom corner portion and the outer dimension of the other end of the legs is such that it can telescopically be received into an opposing top or bottom corner portion.

Also, in accordance with the present invention, the top of the crate is made such that the linear dimensions, e.g., length and/or width, of the top frame, are smaller than the corresponding linear dimensions of the bottom of the crate.

In accordance with a further embodiment of the present invention a crate is provided that accommodates a vehicle within for shipping wherein the vehicle is accommodated at an angle within the crate.

In accordance with a further embodiment of the present invention, a crate is provided with an extension for a bottom frame portion to accommodate vehicles having a dimensional aspect greater than the corresponding structural members of the frame and to allow stacking of crates carrying tilted vehicles.

In accordance with a further embodiment of the present invention, a crate is provided with at least one pivotally mounted leg that pivots from an extended position between a bottom frame portion and a top frame portion to a position lying along a side member or end member of the bottom frame portion.

As used herein “substantially”, “generally”, “relatively”, “approximately”, and “about” are relative modifiers intended to indicate permissible variation from the characteristic so modified. It is not intended to be limited to the absolute value or characteristic which it modifies but rather approaching or approximating such a physical or functional characteristic.

In the following description, reference is made to the accompanying drawings, which are shown by way of illustration to specific non-limiting embodiments in which the invention may be practiced. The following illustrated embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other embodiments may be utilized and that structural changes based on presently known structural and/or functional equivalents may be made without departing from the scope of the invention.

V. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a shipping crate in accordance with the present invention.

FIG. 2 is a perspective view of an exemplary embodiment of an assembled shipping crate in accordance with the present invention.

FIG. 3 is a perspective view of an alternative exemplary embodiment of an assembled shipping crate in accordance with the present invention.

FIG. 4 is a perspective view of a stacked configuration of two shipping crates in accordance with the present invention.

FIG. 5 is a perspective view of telescopically engaged top and bottom frames of an empty crate in accordance with the present invention.

FIG. 6 is a perspective view of a plurality of corresponding top and bottom frames in a stacked configuration in accordance with the present invention.

FIG. 7 is a perspective view of a further alternative exemplary embodiment of an assembled shipping crate in accordance with the present invention.

FIG. 8 is a graphic representation of a crate in accordance with a further embodiment of the invention in which the cargo stored within the crate is stored at an angle.

FIGS. 9A and 9B are perspective side and front views, respectively, of an empty crate in accordance with the embodiment illustrated in FIG. 8.

FIGS. 10A, 10B and 10C are perspective top, side and front views, respectively, of a top frame assembly of a crate in accordance with the embodiment illustrated in FIG. 8.

FIGS. 11A, 11B and 11C are perspective top, side and end views, respectively, of a middle frame assembly of a crate in accordance with the embodiment illustrated in FIG. 8.

FIGS. 12A, 12B and 12C are perspective top, side and end views, respectively, of a rear tire saddle assembly of a crate in accordance with the embodiment illustrated in FIG. 8.

FIGS. 13A, 13B and 13C are perspective top, side and end views, respectively, of a base frame assembly of a crate in accordance with the embodiment illustrated in FIG. 8.

FIG. 14 is a perspective side view of a unitary leg portion in accordance with a further embodiment of the invention.

FIGS. 15A and 15B are perspective top and end views, respectively, of an end bar assembly of a crate according to the embodiment illustrated in FIG. 8.

FIG. 16 is a side view of a crate according to a further embodiment of the invention to which an extension is attached.

FIG. 17 is a perspective view of the front end of the crate of FIG. 16 with the extension removed.

FIG. 18 is a perspective view of the crate of FIG. 16 with a vehicle lying flat.

FIG. 19 is a side view of the crate of FIG. 16 with a vehicle tilted at an angle.

FIG. 20 is a side view of two crates of FIG. 16 with the front end of one vehicle nested under the back end of another vehicle.

FIG. 21 is a side view of the crate of FIG. 16 with a ramp to a tire saddle assembly.

FIG. 22 is a front view of the crate according to a further embodiment of the invention having a pivotally mounting assembly.

FIG. 23 is a perspective view of a pivotally mounting assembly attached to a corner portion of the bottom frame portion of the crate of FIG. 21.

FIG. 24 is a view of FIG. 23 in which a pivotally mounted leg is in a lying position.

FIG. 25 is a top view of the pivotally mounting assembly of FIG. 24.

VII. DETAILED DESCRIPTION OF INVENTION

Exemplary, non-limiting, embodiments of the present invention are discussed in detail below. While specific configurations and dimensions are discussed to provide a clear understanding, it should be understood any disclosed dimensions and configurations are provided for illustration purposes only. A person skilled in the relevant art will recognize that other dimensions and configurations may be used without departing from the spirit and scope of the invention.

FIG. 1 illustrates an exploded view of a shipping crate in accordance with one exemplary embodiment of the present invention. As shown in FIG. 1, a crate 100 according to the present invention comprises a rectangular top frame 1, a corresponding rectangular bottom frame 2 and legs 3. Rectangular top frame 1 comprises two parallel top length bars 1 a and two parallel top cross bars 1 b which are perpendicular to length bars 1 a. Attached at each corner of top frame 1 is a top corner portion 1 c which is fixedly attached to the length and cross bars. Rectangular bottom frame 2 comprises two parallel bottom length bars 2 a and two parallel bottom cross bars 2 b which are perpendicular to length bars 2 a. Attached at each corner of bottom frame 2 is a bottom corner portion 2 c which is fixedly attached to the bottom length and cross bars, 2 a and 2 b.

In accordance with the present embodiment, corner portions 1 c and 2 c, respectively of top frame 1 and bottom frame 2, are end-welded to the top and bottom length and cross bars. End-welding the corner portions in this manner provides for a stronger connection, e.g., between the length and cross bars and the corner portions, than that which is provided by related-art attachment techniques, and also helps to minimize the occurrence of joint-cracking—a phenomenon that readily occurs in related-art crates. An enlarged view of one of the end-welded joints in accordance with the present embodiment is shown within dotted circle 5, in which the welded ends of bottom length bar 2 a and bottom cross bar 2 b are identified by cross-hatching. It should be noted that according to the present embodiment, every corner joint, i.e., where corner portions 1 c and 2 c are joined to corresponding length and cross bars 1 a, 1 b and 2 a, 2 c, respectively, of the top and bottom frames, are end-welded in similar fashion to that which is shown in the blow-up circle 5 of FIG. 1.

In addition to end-welding the corner portions of the respective frames to the length and cross bars, i.e., where the ends of the length and cross bars are welded directly to two respective perpendicular faces of the corner portions, other means of attaching the corner portions can also be effectively utilized. For example, the respective ends of the length and cross bars can be welded together and the corner portion can then be attached to either the inside or the outside of the corner joint thus created. Also, the corner portions could be created integral with either the length or cross bar and then attached to the other of the length or cross bar that makes up that corner.

Top and bottom frames, 1 and 2, in this exemplary embodiment are each made of hollow metal bars. For example, in the embodiment illustrated in FIG. 1, length bars 1 a and 2 a and cross bars 1 b and 2 b are each made of hollow rectangular metal tubes the cross-section of which is 2.540 cm (1 inch) wide by 5.080 cm (2 inches) high. It should be recognized, however, that the present invention is not limited to using hollow metal tubing, or material with these specific dimensions. For example, according to an alternative exemplary embodiment, not illustrated, the length and cross bars are made of a solid material, such as metal, plastic, composite material, or any other material of suitable strength. Additionally, the cross-sectional dimensions of the length and cross bars can be any suitable dimension that provides adequate rigidity to the frames.

As shown in FIG. 2, the four legs 3 are provided at the corners of the crate when it is assembled. As indicated by the dotted-arrow lines in FIG. 1, legs 3 are attached at their respective ends to the top and bottom frame portions, 1 and 2. Legs 3 in this embodiment are also made of tubular metal.

As indicated by the dotted-arrow lines in FIG. 1 and shown in the assembled crate of FIG. 2, each top corner portion 1 c is received into a respective top end of a leg 3 and the bottom end of each leg 3 is received into a respective bottom corner portion 2 c of bottom frame 2. Accordingly, the top corner portions 1 c, legs 3 and bottom corner portions 2 c telescopically engage one another.

In accordance with this embodiment, in order to accommodate the telescopic engagement described, the outer dimension of the top corner portions 1 c is smaller that the inner dimension of the corresponding top ends of legs 3. Further, the outside dimension of the bottom ends of legs 3 is smaller than the inner dimension of the bottom corner portions 2 c. For example, according to one embodiment, top corner portions 1 c are made of rectangular metal tubing which has a cross sectional area that is 3.175 cm by 3.175 cm (1¼ inches by 1¼ inches), and legs 3 are made of rectangular metal tubing which has a cross sectional area that is 3.81 cm by 3.81 cm (1½ inches by 1½ inches). Accordingly, as long as legs 3 are made from tubular metal which has a wall thickness of 0.3175 cm (⅛ inch) or less, top corner portions 1 c will fit inside the top ends of legs 3.

Further, in accordance with the embodiment shown in FIGS. 1 and 2, bottom corner portions 2 c are made of metal tubing which has a cross-sectional area that is 4.445 cm by 4.445 cm (1¾ inches by 1¾ inches). Accordingly, as illustrated in blow-up circle 6 in FIG. 2, as long as corner portions 2 c are made from tubular metal which has a wall thickness of 0.3175 cm (⅛ inch) or less, the bottom ends of legs 3 will fit inside bottom corner portions 2 c.

Also, in accordance with this embodiment, the overall length and the overall width of the top frame 1 are made shorter than the overall length and width of the bottom frame 2. Specifically, in addition to the top corner portions having smaller dimensions, e.g., 3.175 cm by 3.175 cm (1¼ inches by 1¼ inches), than the bottom corner portions, e.g., 4.445 cm by 4.445 cm (1¾ inches by 1¾ inches), the length and cross bars, 1 a and 1 b, of the top frame 1 are each made shorter than the corresponding length and cross bars, 2 a and 2 b, of the bottom frame 2. For example, the top length bars are 2.153 m (84¾ inches) long and the top cross bars are 1.143 m (45 inches) long. The corresponding length and cross bars of the bottom frame are 2.146 m (84½ inches) and 1.130 m (44½ inches) long, respectively. Accordingly, in this example, the overall length of the top frame 1 is 2.216 m (87¼ inches) and the overall width is 1.207 m (47½ inches). Correspondingly, the overall length of the bottom frame is 2.235 m (88 inches) and the overall width is 1.213 m (47¾ inches). By having the top frame dimensions smaller than the bottom frame dimensions, the racking effect is minimized.

Referring to FIG. 3, an alternative exemplary embodiment of the present invention is shown. Substantially all of the structural components of the crate illustrated in FIG. 3 in accordance with this alternative embodiment are similar to the structural components shown in FIGS. 1 and 2, with a few exceptions as discussed in detail below. Accordingly, like components are labeled in FIG. 3 with the same reference number as the corresponding component in FIGS. 1 and 2.

One difference between the crate shown in FIG. 3 and the crate shown in FIGS. 1 and 2 is the addition of nub portion 1 d, which extends above the top of length bars 1 a and cross bars 1 b on each of the corners of the top frame 1. Nub portions 1 d can be integral with top corner portions 1 c or they can be separate components provided on top of, or adjacent to, top corner portions 1 c. As shown in blow-up circle 7 in FIG. 3, top corner portion 1 c comprises nub portion 1 d, i.e., nub portion 1 d is integral with corner portion 1 c. As shown with respect to the embodiment of FIG. 3, nub portion 1 d extends above the location on corner portion 1 c where length bar 1 a and cross bar 1 b are attached to corner portion 1 c. The purpose of nub portions 1 d will become apparent in the discussion below in regard to FIGS. 4-6.

Referring to FIG. 4, an embodiment of the present invention is illustrated which comprises two similar shipping crates 100 stacked on top of one another. The two shipping crates shown in FIG. 4 are structurally similar to the crate 100 shown in FIG. 3. Two or more crates are stacked, for example, to maximize storage space when the full crates are in transit or when the crates are otherwise stored. According to the present embodiment, to accommodate easy stacking of the crates, a receiving portion 2 d is provided at each corner on the lower side of bottom frame 2 of each crate 100. Receiving portions 2 d receive nubs 1 d from the top frame 1 and, thus, when the crates are stacked, the upper crate does not easily become separated from the lower crate.

In the embodiment shown, receiving portion 2 d is integral with bottom corner portion 2 c. However, one skilled in the art will recognize that other configurations are also possible. For example, receiving portion 2 d can be a separate structure (not shown) attached to the bottom of each of the corner portions 2 d.

FIG. 5 illustrates a further advantageous aspect of the present invention. In particular, as illustrated in FIG. 5, legs 3 have been removed from crate 100, for example after the crate has been used to deliver its cargo and it is intended to return the shipping crate or otherwise deliver the empty crate to another location. With legs 3 removed, top frame 1 is telescopically engaged with bottom frame 2 directly. That is, due to the dimensions of the top and bottom frame components, for example as discussed above in regard to the embodiment of FIG. 2, each of the top corner portions 1 c is inserted into a corresponding bottom corner portion 2 c. In similar fashion to the embodiment discussed above, top corner portions 1 c have an outer dimension that is less than an inner dimension of bottom corner portions 2 c.

For example, top corner portions 1 c are made of tubular metal with a rectangular cross-sectional outer dimension of 3.175 cm (1¼ inches) by 3.175 cm (1¼ inches). Further, bottom corner portions are also made of tubular metal but with a rectangular cross-sectional outer dimension of 4.445 cm (1¾ inches) by 4.445 cm (1 3/4 inches). Accordingly, using these exemplary dimensions, as long as the tubular metal used to make bottom corner portions 2 c has a wall thickness of less than or equal to 0.635 cm (¼ inch), the top corner portions 1 c will fit into bottom corner portions 2 c.

When the top and bottom frames of an empty shipping crate in accordance with the present invention are stacked in this manner, a significant amount of space is saved in comparison to that which is occupied by other empty, related art, shipping crates. Accordingly, significant efficiencies can be realized by the shipper and/or supplier of the goods shipped.

FIG. 6 illustrates a plurality of empty shipping crates stacked on top of each other in accordance with the present invention. As shown, nub portions 1 d on the top frames 1 are received into the receiving portions 2 d, as discussed above in detail with respect to FIG. 3. Accordingly, as discussed above in regard to stacking full shipping crates, empty shipping crates can be telescopically combined and stacked on top of one another, thus, creating a sturdy stack of empty crates and also saving significant space within the return shipper's payload.

FIG. 7 illustrates a further alternative exemplary embodiment of the present invention. Several of the structural components of the crate illustrated in FIG. 7 in accordance with this alternative embodiment are the same as the structural components shown in FIGS. 1 and 2, with a few additions, as discussed in detail below. Accordingly, like components are labeled in FIG. 7 with the same reference number as the corresponding component in FIGS. 1 and 2.

The shipping crate illustrated in FIG. 7 in addition to including the telescoping corner joints similar to that which is described above in regard to FIGS. 1-6, also comprises plates 15, stringers 16, full width bar supports 17, and partial width bar supports 18 a-18 d.

As for other components described herein, stringers 16 according to this embodiment are constructed of tubular metal. Stringers 16 extend between bottom cross bars 2 b and provide additional strength to the overall structure of the base frame 2. Additionally, plates 15 are made of flat metal and respectively extend between, and are attached to, a stringer 16 and a bottom length bar 2 a. Partial width bar supports 18 a-18 d each extend between, and are attached to, a stringer at one end thereof and a bottom length bar 2 a at another end. According to the exemplary configuration shown in FIG. 7, partial width bar supports 18 a-18 d can be paired such that the pairs are provided on opposite sides of the bottom frame 2. Configuring the partial width bar supports in this manner enables them to be used as tire locators and/or supports in the event a vehicle with corresponding tires is shipped within the shipping crate.

Full width bar supports 17 extend between bottom length bars 1 a and are connected at respective ends thereof. Full width bar supports 17 can be used, for example, to support a certain vehicle assembly in the event a vehicle with a corresponding assembly, such as a fork assembly on an ATV, is shipped within the shipping crate. Additional full and partial width bar supports can also be added, as needed, and certain supports can be removed if not needed.

FIG. 8 illustrates an even further alternative exemplary embodiment of the present invention. Several of the structural components of the crate illustrated in FIG. 8 in accordance with this additional embodiment are similar to structural components shown in FIGS. 1 and 2, with some additions, as discussed in detail below.

FIGS. 9A and 9B illustrate side and front views, respectively, of an empty crate assembly consistent with the embodiment of FIG. 8. As FIGS. 9A and 9B illustrate, a crate 300 in accordance with this embodiment provides a top frame portion 301 and a bottom frame portion 302. The top and bottom frame portions shown in FIG. 9 are somewhat similar to the top and bottom frame portions illustrated in FIG. 1 in that the corner portions of the top frame portion are constructed such that they can insert into the corner portions of the bottom frame portion, consistent with the previous embodiments. Additionally, however, the crate illustrated in FIGS. 9A and 9B also provides a middle frame portion disposed between the top and bottom frame portions. Top leg portions 305 are mated with the corner portions of the top and middle frame portions and bottom leg portions are mated with the corner portions of the middle and bottom frame portions.

For example, the top leg portions 305 have an inside dimension, e.g., diameter, that is larger than the outer dimension of the corner portion of the top frame portion. Accordingly, the corner portions of the top frame portion can be inserted into, e.g., telescopically engage, one end of the top leg portions 305. The other end of the top leg portions are inserted into the corner portions of the middle frame portion. Additionally, bottom leg portions 306 have an outside dimension that is smaller than the inside dimension of the corner portion of the middle frame portion. Accordingly, one end of the bottom leg portions can be inserted into, e.g., telescopically engage, the corner portions of the middle frame portion. The other end of the bottom leg portions are inserted into the corner portions of the bottom frame portion.

In accordance with a further embodiment, the top and bottom leg portions are constructed as a single integrated structure 500 as shown in FIG. 14. A sleeve 501 is placed around the outside of leg 500 and fixedly attached thereto at a location slightly offset from the midsection of leg 500. In accordance with this embodiment, leg 500 has an outer dimension that is less than the inner dimension of the corner portions of the middle frame portion. Accordingly, leg 500 can insert through the corner portion from the underside and slide up to the upper part of the sleeve 501. The top end of leg 500 telescopically engages with the corner of the top frame portion and the bottom end of leg 500 telescopically engages the corner portions of the bottom frame portion.

As shown in FIGS. 10A, 10B and 10C, top frame portion 301 includes length bars 301 a, cross bars 301 b and corner portions 301 c. The manner by which each of the length and cross bars are attached to the corner portions 301 c is similar to the manner by which these corresponding elements are assembled for the previous embodiment described with respect to FIG. 1.

FIGS. 11A, 11B and 11C illustrate top, side and end views, respectively, of the middle frame assembly of the crate shown in FIG. 9. The middle frame assembly of the crate of FIG. 9 includes two structures 303 as illustrated in FIG. 11. In particular, the overall middle frame assembly of a crate in accordance with this embodiment includes two structures 303 each of which includes a length bar 303 a and two end pieces 303 b. Length bar 303 a is attached between the two end pieces 303 b by butt-welding or a similar process.

FIGS. 12A, 12B and 12C illustrate top, side and end views, respectively, of a tire saddle assembly 400 for the crate shown in FIG. 9. In particular, tire saddle assembly 400 includes two end pieces 402 between which are connected two inverted “L-shaped” tire support members 401. As shown in FIGS. 12A and 12B, the two L-shaped tire supports are spaced apart a variable distance d creating a “V-shaped” area T into which a tire or tires is supported when the saddle assembly is connected to middle frame assemblies 303. Attachment portions 403 are attached to end pieces 402 and create an area H which hooks onto or otherwise connects to the length members 303 a.

The saddle assembly 400 is operable to support one end of the cargo stored and shipped within the crate, as illustrated in FIG. 8. For example, as shown, when the crate is used to ship an ATV, the saddle portion 400 supports the front or rear tires of the ATV. The opposite set of tires is supported by the bottom frame portion, described below. In this manner, the ATV stored within the crate is stored at an angle relative to the top and bottom frame portions. Accordingly, a crate in accordance with this embodiment takes up less space in the horizontal direction or, in other words, in the direction parallel to the ATV.

According to one exemplary embodiment, as shown in FIG. 12B, an angle formed with respect to the slanted portion of the “L-shaped” cross member and the attachment portions 403 is approximately 40 degrees. However, a skilled artisan would know that other angles are possible depending on the size of the tires, or other object, being supported. Accordingly, the ATV stored within the crate is stored with one set of tires, e.g., either the front or rear set, being supported by the saddle portion of the middle frame portion and the other set of tires at the other end of the ATV is supported by the bottom frame portion.

As shown in FIGS. 13A, 13B and 13C, bottom, or base, frame portion 302 includes length bars 302 a, cross bars 302 b, end members 302 c, bottom tire support members 302 d and corner portions 302 e. The manner by which each of the length (302 a) and end members (302 c) are attached to the corner portions 302 e is similar to the manner by which these corresponding elements are assembled for the previous embodiment described with respect to FIG. 1.

Also, in accordance with one exemplary configuration of base frame assembly 302, as shown, an area R is created between the tire support members 302 d and one of the cross bars 302 b. When a crate is assembled in accordance with this embodiment, the tires of one end of a vehicle, such as an ATV, are supported within area R.

In addition to providing a middle frame portion with a saddle portion for supporting cargo at an angle, the embodiment described, for example, with reference to FIGS. 8-13 is also constructed to include the telescoping feature described in regard to the other embodiments. In particular, as mentioned above, the corner portions 301 c of the top frame portion.

FIG. 16 illustrates an alternative embodiment of a crate according to the present invention. Several of the structural components of the crate are similar to structural components shown in the preceding figures. For example, the crate has corner portions of the top frame portion that are constructed such that they can insert into the corner portions of the bottom frame portion, consistent with the previous embodiments. A middle frame portion is disposed between the top and bottom frame portions. Top leg portions are mated with the corner portions of the top and middle frame portions. Bottom leg portions are mated with the corner portions of the middle and bottom frame portions, as shown in FIGS. 8 and 9A-9B. The middle frame portion may be as shown in FIGS. 11A-11C. A tire saddle assembly may be provided for the crate according to FIGS. 12A-12C.

As shown in FIG. 16, crate 600 has a top frame portion 605 and a bottom frame portion 610. Bottom frame portion 610 includes side members 612, full length bars 615, partial length bars 620, full width cross bars 625, partial width cross bars 630, end members 635, and corner portions 640. The full width cross bars 625 may have ends positioned on top sides of opposing side members or on bottom sides of opposing side members. The crate 600 has a middle frame portion 645 and a saddle portion 650. According to the present invention, the crate 600 comprises a removably connectable extension 655 to the bottom frame portion.

As shown in FIG. 17, the full length bars 615 may have openings 660 located on an end member 635. According to the present invention, partial length bars 620 may be positioned above the full length bars 615 and have openings 665 positioned above end member 635.

The extension 655 comprises mating portions 667 that may be removably insertable into at least one of the openings 665 of the partial length bars 620 or openings 660 in the full length bars 615. The extension 655 is two-sided and the maybe flipped prior to inserting the mating portions 667 into at least one of openings 660 or openings 665 depending upon the use of the extension as discussed below. The extension allows for the conversion of a crate, for example the crate of FIG. 8 or the crate of FIG. 16, to accommodate long vehicles, thereby allowing the crate to be used with a variety of vehicles having different sizes in a cost-efficient manner.

The extension 655 comprises a plurality of support members each fixedly attached to one or more corner portions. As illustrated, the extension 655 comprises length bars 668, end members 670, side bars 677, and corner portions 680. The extension also comprises tire support members 675.

As illustrated in FIG. 18, the extension 655 may be oriented so that corner portions 680 face downwards to contact the ground or floor, for example, by inserting the mating portions 667 of the extension into openings 665 of the partial length bars 620. The support members 675 of the extension form an area R. When a crate is assembled in accordance with this embodiment, the tires of one end of a vehicle are supported within area R. In this embodiment, the vehicle lies flat, parallel to the floor, without being positioned at an angle relative to the top and bottom frame portions.

As illustrated in FIG. 19, the extension 655 may be oriented such that the corner portions 680 face upwards, for example, by flipping the extension 655 as illustrated in FIG. 18. In this orientation, the entire extension is above or off the ground or floor. The support members 675 of the extension form an area R. In this embodiment, a vehicle may be angled or tilted within the crate, having a front set of tires in area R of the extension and a rear set of tires in the saddle portion of the middle frame portion. Thus, a vehicle may be positioned or stored within a crate at an angle relative to the top and bottom frame portions.

An advantage of the embodiment illustrated in FIG. 19 is that it allows the extension 655 of one crate 600 to be positioned over a back end of a crate 601 in front of it, as shown in FIG. 20. This orientation allows at least two crates to be arranged or stacked in series in a horizontal direction. Thus, at least two crates housing tilted vehicles may be stacked, with the front end of one vehicle being positioned under the back end of another vehicle. Accordingly, the at least two nested crates take up less space in the horizontal direction. The number of vehicles that can be transported is increased, thus saving at least one of transportation costs, fuel costs, or transportation fees.

The end of a vehicle may be placed in the saddle portion of the middle frame portion using at least one of a ramp or a hoist. As shown in FIG. 21, the position of a ramp 685 allows for a vehicle to be backed into a crate such that the rear wheels are situated in the saddle portion 650. Alternatively, a rear end of a vehicle may be hoisted into the saddle portion.

FIG. 22 illustrates an alternative embodiment of a crate according to the present invention having at least one pivotally mounted leg. Several of the structural components of the crate are similar to structural components shown in the preceding figures, with some changes as discussed below.

Crate 700 may have a top frame portion and a bottom frame portion as discussed in previous embodiments. A middle frame portion may be disposed between the top and bottom frame portions.

Crate 700 comprises at least one leg that is pivotally mounted. In embodiments, the pivotally mounted leg pivots from an extended position (FIG. 23) between the bottom frame portion and the top frame portion to a position lying along a side member or end member of the bottom frame portion (FIG. 22). In other embodiments, at least one leg extending between the bottom frame portion and a middle frame portion and/or between the middle frame portion and the top frame portion may be pivotally mounted.

In certain embodiments, at least one pivotally mounting assembly 705 comprises an anchor 710 and a pivotally mounted leg 715 connected to the anchor 710. The anchor 710 may be removably or fixedly attached to a corner portion of a bottom frame portion or a middle frame portion. In embodiments, the anchor 710 is insertable into a corner portion. Pivotally mounted leg 715 comprises substantially the entire length of the pivotally mounting assembly when the leg is in an extended position (FIG. 23). Pivotally mounted leg 715 may be fastened to the anchor 710 such that the leg 715 may be pivoted while the anchor 710 remains upright and connected to a corner portion (FIG. 24). Leg 715 may be pivotally mounted to the anchor 710 with a fastener, for example, a bolt and tie as illustrated in FIG. 25.

In certain embodiments, the pivotally mounted leg 715 may be connected to the anchor 710 via two plates, as illustrated in FIGS. 24-25. Each plate extends from a side of the pivotally mounted leg 715 to a respective side of the anchor 710. The plates are attached to the anchor 710 in a pivotally mounted manner, for example with a bolt and tie, thereby allowing the leg 715 to pivot between an upright position and a lying position while the anchor remains stationary. The plates may be attached to the pivotally mounted leg in any effective manner, for example, by welding, soldering, adhesive, nails, screws, bolts, and the like.

While various aspects of the present invention have been particularly shown and described with reference to the exemplary, non-limiting, embodiments above, it will be understood by those skilled in the art that various additional aspects and embodiments may be contemplated without departing from the spirit and scope of the present invention.

For example, a skilled artisan would understand that various materials can be used to construct the shipping crate disclosed as can various dimensions and configurations. Also, even though the embodiments described above disclose a telescoping leg-corner configuration and a corner-corner configuration, where the upper-most component (e.g., top corner portion) fits into the middle component (e.g., leg), which in turn fits into the lower-most component (e.g., bottom corner portion), a skilled artisan would understand that the order can be reversed, i.e., the lower-most component could fit into the middle component, which in turn could fit into the upper-most component. It would be understood that a device or method incorporating any of the additional or alternative details mentioned above would fall within the scope of the present invention as determined based upon the claims below and any equivalents thereof.

Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims. 

1. A stack of at least two crates, comprising: a top frame portion comprising a plurality of top support members each fixedly attached to one or more top corner portions; a middle frame portion comprising a plurality of middle support members each fixedly attached to one or more middle corner portions; a bottom frame portion comprising a plurality of bottom support members each fixedly attached to one or more bottom corner portions, and having openings positioned above an end member; and an extension removably connectable to the openings of the bottom frame portion, said extension comprising a plurality of support members each fixedly attached to one or more corner portions, wherein, when the one or more corner portions of the extension face upwards, said extension is above the ground and is placed over a back end of another crate, thereby allowing at least two crates to be stacked in a horizontal direction.
 2. A stack of at least two crates according to claim 1, wherein said extension comprises mating portions that are insertable into said openings.
 3. A stack of at least two crates according to claim 1, wherein, when the one or more corner portions of the extension face downwards, said extension contacts the ground.
 4. A stack of at least two crates as claimed in claim 3, wherein cargo stored within said crate lies flat without being positioned at an angle relative to said top frame portion and said bottom frame portion.
 5. A stack of at least two crates as claimed in claim 4, wherein the cargo comprises a vehicle and wheels of the vehicle are placed within the extension.
 6. A stack of at least two crates according to claim 1, wherein, when the one or more corner portions of the extension face upwards, said extension is above the ground.
 7. A stack of at least two crates according to claim 1, wherein said support members support at least a portion of cargo stored within a crate.
 8. A stack of at least two crates as claimed in claim 1, wherein said middle frame portion comprises a saddle portion connected between two of the middle support members.
 9. A stack of at least two crates as claimed in claim 8, wherein cargo stored within said crate is positioned at an angle relative to said top and bottom frame portions.
 10. A stack of at least two crates as claimed in claim 8, wherein the cargo comprises a vehicle and one set of wheels of the vehicle is placed within said extension and the other set of wheels is placed in the saddle portion.
 11. A stack of at least two crates as claimed in claim 8, further comprising at least one of a ramp or a hoist to place an end of a vehicle within the saddle portion.
 12. A stack of at least two crates as claimed in claim 1, further comprising: a plurality of top leg portions disposed respectively between one of the middle corner portions and one of the top corner portions; and a plurality of bottom leg portions disposed respectively between one of the middle corner portions and one of the bottom corner portions. 